Gaseous fuel compression and control system and method

Abstract

A gaseous fuel compression and control system is disclosed which utilizes a helical flow compressor/turbine integrated with a permanent magnet motor/generator and driven by a torque controlling inverter to compress or expand gaseous fuels, precisely control fuel pressure and flow, and precisely control the operations (speed, combustion temperature and output power) of a gaseous fuel fired turbogenerator.

What we claim is: 
     
       1. A gaseous fuel compression and control system, comprising: a turbogenerator set including a turbogenerator and turbogenerator power controller, said turbogenerator including a compressor, a turbine, a combustor with a plurality of gaseous fuel nozzles and a plurality of air inlets, a recuperator, and a permanent magnet motor/generator;   a helical flow compressor/turbine for supplying pressurized gaseous fuel to the gaseous fuel nozzles of said turbogenerator combustor, said turbogenerator compressor supplying compressed air to said air inlets of said turbogenerator combustor;   a motor operably associated with said helical flow compressor/turbine to drive said helical flow compressor/turbine; and   a helical flow compressor/turbine motor inverter drive operably associated with said helical flow compressor/turbine motor to provide electrical power to said helical flow compressor/turbine motor and receive operational data from said helical flow compressor/turbine motor, said helical flow compressor/turbine motor inverter drive also operably associated with said turbogenerator power controller to receive control signals from said turbogenerator power controller, said turbogenerator power controller also receiving operational data from said helical flow compressor/turbine motor drive inverter and turbogenerator parameter signals from said turbogenerator.   
     
     
       2. The gaseous fuel compression and control system of claim 1 wherein said motor for said helical flow compressor/turbine is a permanent magnet motor/generator. 
     
     
       3. The gaseous fuel compression and control system of claim 2 wherein said helical flow compressor/turbine and said permanent magnet motor/generator share a common shaft. 
     
     
       4. The gaseous fuel compression and control system of claim 1 wherein said operational data received by said helical flow compressor/turbine motor inverter from said helical flow compressor/turbine motor includes motor phase data. 
     
     
       5. The gaseous fuel compression and control system of claim 1 wherein said operational data received by said helical flow compressor/turbine motor inverter from said helical flow compressor/turbine motor includes motor speed data. 
     
     
       6. The gaseous fuel compression and control system of claim 1 wherein said operational data received by said helical flow compressor/turbine motor inverter from said helical flow compressor/turbine motor includes both motor phase data and motor speed data. 
     
     
       7. The gaseous fuel compression and control system of claim 1 wherein said control signal received by said helical flow compressor/turbine motor inverter drive from said turbogenerator power controller includes a torque control signal. 
     
     
       8. The gaseous fuel compression and control system of claim 1 wherein said control signal received by said helical flow compressor/turbine motor inverter drive from said turbogenerator power controller includes a speed control signal. 
     
     
       9. The gaseous fuel compression and control system of claim 1 wherein said control signal received by said helical flow compressor/turbine motor inverter drive from said turbogenerator power controller includes both a maximum speed control signal and a torque control signal. 
     
     
       10. The gaseous fuel compression and control system of claim 1 wherein said turbogenerator parameter signal received by said turbogenerator power controller includes turbogenerator speed. 
     
     
       11. The gaseous fuel compression and control system of claim 1 wherein said turbogenerator parameter signal received by said turbogenerator power controller includes turbogenerator turbine exhaust gas temperature. 
     
     
       12. The gaseous fuel compression and control system of claim 1 wherein said turbogenerator parameter signal received by said turbogenerator power controller includes both turbogenerator speed and turbogenerator turbine exhaust gas temperature. 
     
     
       13. The gaseous fuel compression and control system of claim 1 wherein said helical flow compressor/turbine inlet includes a pressure sensor to provide an inlet pressure signal to said turbogenerator power controller. 
     
     
       14. The gaseous fuel compression and control system of claim 1 wherein said helical flow compressor/turbine outlet includes a pressure sensor to provide an outlet pressure signal to said turbogenerator power controller. 
     
     
       15. The gaseous fuel compression and control system of claim 1 wherein said helical flow compressor/turbine inlet includes a pressure sensor to provide an inlet pressure signal to said turbogenerator power controller and said helical flow compressor/turbine outlet includes a pressure sensor to provide an outlet pressure signal to said turbogenerator power controller. 
     
     
       16. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing including a permanent magnet stator positioned at one end thereof,   a shaft rotatably supported within said housing;   a permanent magnet rotor mounted on said shaft at said one end thereof and operably associated with said permanent magnet stator; and   an impeller mounted at the other end of said shaft, said impeller having at least one row of a plurality of blades,   said housing including a generally horseshoe shaped fluid flow stator channel operably associated with each row of the plurality of impeller blades, a fluid inlet at one end of said generally horseshoe shaped fluid flow stator channel, and a fluid outlet at the other end of said generally horseshoe shaped fluid flow stator channel, the fluid in said generally horseshoe shaped fluid flow stator channel proceeding from said fluid inlet to said fluid outlet while following a generally helical flow path with multiple passes through said impeller blades.   
     
     
       17. The gaseous fuel compression and control system of claim 16 wherein said impeller blades are straight radial blades. 
     
     
       18. The gaseous fuel compression and control system of claim 16 wherein said impeller blades are curved blades having a generally radial blade tip. 
     
     
       19. The gaseous fuel compression and control system of claim 18 wherein said curved impeller blades have a leading edge with a greater curve than the curve of the blade root. 
     
     
       20. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing including a permanent magnet stator positioned at one end thereof;   a shaft rotatably supported within said housing;   a permanent magnet rotor mounted on said shaft at said one end thereof and operably associated with said permanent magnet stator; and   an impeller mounted at the other end of said shaft, said impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the outer periphery of said impeller,   said housing including two generally horseshoe shaped fluid flow stator channels with one of said two generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of impeller blades and the other of said two generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of impeller blades, said housing also including a stripper plate disposed radially outward from said impeller, a fluid inlet at one end of each of said two generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of each of said two generally horseshoe shaped fluid flow stator channels, the fluid in each of said generally horseshoe shaped fluid flow stator channels proceeding from its fluid inlet to its fluid outlet while following a generally helical flow path with multiple passes through said impeller blades operably associated with said generally horseshoe shaped fluid flow stator channel.   
     
     
       21. The rotating machine of claim 20 wherein said impeller blades are straight radial blades. 
     
     
       22. The rotating machine of claim 20 wherein said impeller blades are curved blades having a generally radial blade tip. 
     
     
       23. The rotating machine of claim 22 wherein said curved impeller blades have a leading edge with a greater curve than the curve of the blade root. 
     
     
       24. The rotating machine of claim 20 wherein said stripper plate has a thickness slightly greater than the thickness of said impeller to provide a running clearance for said impeller. 
     
     
       25. The rotating machine of claim 20 and in addition, a bore seal tube disposed between said permanent magnet stator and said permanent rotor to prevent the working fluid from contacting said permanent magnet stator. 
     
     
       26. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing including a permanent magnet stator positioned at one end thereof;   a shaft rotatably supported within said housing;   a permanent magnet rotor mounted on said shaft at one end thereof and operably associated with said permanent magnet stator;   a low pressure impeller mounted at the other end of said shaft, said low pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the radially outward edge of said low pressure impeller;   a high pressure impeller mounted at the other end of said shaft, said high pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the radially outward edge of said high pressure impeller;   said housing including a mid stator channel plate disposed between said low pressure impeller and said high pressure impeller, a first pair of generally horseshoe shaped fluid flow stator channels with one of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of low pressure impeller blades and the other of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of low pressure impeller blades, and a second pair generally horseshoe shaped fluid flow stator channels with one of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of high pressure impeller blades and the other of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of high pressure impeller blades,   said housing also including a low pressure stripper plate disposed radially outward of said low pressure impeller, a high pressure stripper plate disposed radially outward of said high pressure impeller, a fluid inlet at one end of each of said first pair of generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of said first pair of said generally horseshoe shaped fluid flow stator channels and a fluid inlet at one end of each of said second pair of generally horseshoe shaped fluid flow stator channels and a fluid outlet at the other end of said second pair of said generally horseshoe shaped fluid flow stator channels, said inlet of said second pair of said generally horseshoe shaped fluid flow stator channels communicating with the outlet of said first pair of said generally horseshoe shaped fluid flow stator channels,   the fluid in each of said generally horseshoe shaped fluid flow stator channels making multiple generally helical passes between said generally horseshoe shaped fluid flow stator channel and said impeller blades as the fluid proceeds from said inlet to said outlet of said generally horseshoe shaped fluid flow stator channel.   
     
     
       27. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing;   a permanent magnet stator mounted within said housing at one end thereof;   a shaft rotatably supported within said housing by a pair of journal bearings;   a permanent magnet rotor mounted on said shaft between said pair of journal bearings, said permanent magnet rotor disposed on said shaft to rotate within said permanent magnet stator mounted at one end of said housing;   a low pressure impeller mounted at the other end of said shaft, said low pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the radially outward edge of said low pressure impeller;   a high pressure impeller mounted at the other end of said shaft, said high pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the radially outward edge of said high pressure impeller;   said housing including a mid stator channel plate disposed between said low pressure impeller and said high pressure impeller, a first pair of generally horseshoe shaped fluid flow stator channels with one of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of low pressure impeller blades and the other of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of low pressure impeller blades, and a second pair generally horseshoe shaped fluid flow stator channels with one of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of high pressure impeller blades and the other of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of high pressure impeller blades,   said housing also including a low pressure stripper plate disposed radially outward of said low pressure impeller, a high pressure stripper plate disposed radially outward of said high pressure impeller, a fluid inlet atone end of each of said first pair of generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of said first pair of said generally horseshoe shaped fluid flow stator channels and a fluid inlet at one end of each of said second pair of generally horseshoe shaped fluid flow stator channels and a fluid outlet at the other end of said second pair of said generally horseshoe shaped fluid flow stator channels, said inlet of said second pair of said generally horseshoe shaped fluid flow stator channels communicating with the outlet of said first pair of said generally horseshoe shaped fluid flow stator channels,   the fluid in each of said generally horseshoe shaped fluid flow stator channels making multiple generally helical passes between said generally horseshoe shaped fluid flow stator channel and said impeller blades as the fluid proceeds from said inlet to said outlet of said generally horseshoe shaped fluid flow stator channel.   
     
     
       28. The helical flow compressor/turbine permanent magnet motor of claim 27 wherein said plurality of impeller blades is straight radial blades. 
     
     
       29. The helical flow compressor/turbine permanent magnet motor of claim 27 wherein said plurality of impeller blades is curved blades. 
     
     
       30. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing including a permanent magnet stator positioned at one end thereof;   a shaft rotatably supported within said housing;   a permanent magnet rotor mounted on said shaft at said one end thereof and operably associated with said permanent magnet stator;   a low pressure impeller mounted at the other end of said shaft, said low pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the outer periphery of said impeller;   a high pressure impeller mounted at the other end of said shaft, said high pressure impeller having two rows each of a plurality of blades, with one row of said plurality of blades disposed on either side of the outer periphery of said high pressure impeller;   said housing including a mid stator channel plate disposed between said low pressure impeller and said high pressure impeller, a first pair of generally horseshoe shaped fluid flow stator channels with one of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of low pressure impeller blades and the other of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of low pressure impeller blades, and a second pair generally horseshoe shaped fluid flow stator channels with one of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of high pressure impeller blades and the other of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of high pressure impeller blades,   said housing also including a low pressure stripper plate disposed radially outward of said low pressure impeller and a high pressure stripper plate disposed radially outward of said high pressure impeller, said low pressure stripper plate having a slightly greater thickness than said low pressure impeller and said high pressure stripper plate having a slightly greater thickness than said high pressure impeller,   said housing further including a fluid inlet at one end of each of said first pair of generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of said first pair of said generally horseshoe shaped fluid flow stator channels and a fluid inlet to one end of each of said second pair of generally horseshoe shaped fluid flow stator channels and a fluid outlet at the other end of each of said second pair of said generally horseshoe shaped fluid flow stator channels, said inlet of said second pair of said generally horseshoe shaped fluid flow stator channels communicating with the outlet of said first pair of said generally horseshoe shaped fluid flow stator channels,   the fluid in each of said generally horseshoe shaped fluid flow stator channels making multiple generally helical passes between said generally horseshoe shaped fluid flow stator channel and said impeller blades as the fluid proceeds from said inlet to said outlet of said generally horseshoe shaped fluid flow stator channel.   
     
     
       31. The rotating machine of claim 30 wherein said impeller blades are straight radial blades. 
     
     
       32. The rotating machine of claim 30 wherein said impeller blades are curved blades having a generally radial blade tip. 
     
     
       33. The rotating machine of claim 32 wherein said curved impeller blades have a leading edge with a greater curve than the curve of the blade root. 
     
     
       34. The rotating machine of claim 30 and in addition, a bore seal tube disposed between said permanent magnet stator and said permanent rotor to prevent the working fluid from contacting said permanent magnet stator. 
     
     
       35. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing;   a permanent magnet stator mounted within said housing at one end thereof;   a shaft rotatably supported within said housing by a pair of journal bearings;   a permanent magnet rotor mounted on said shaft between said pair of journal bearings, said permanent magnet rotor disposed on said shaft to rotate within said permanent magnet stator mounted at one end of said housing;   a bore seal tube disposed between said permanent magnet rotor and said permanent magnet stator to prevent operating fluid from contacting said permanent magnet stator;   a low pressure impeller mounted at the other end of said shaft, said low pressure impeller having two rows each of a plurality of radial blades, with one row of said plurality of radial blades disposed on either side of the outer periphery of said low pressure impeller;   a high pressure impeller mounted at the other end of said shaft adjacent to said low pressure impeller, said high pressure impeller having two rows each of a plurality of radial blades, with one row of said plurality of radial blades disposed on either side of the outer periphery of said high pressure impeller;   said housing including a low pressure stripper plate disposed radially outward of said low pressure impeller and a high pressure stripper plate disposed radially outward of said high pressure impeller, said low pressure stripper plate having a slightly greater thickness than said low pressure impeller to provide rotational clearance for said low pressure impeller, and said high pressure stripper plate having a slightly greater thickness than said high pressure impeller to provide rotational clearance for said high pressure impeller,   said housing further including a fluid inlet at one end of each of said generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of each of said generally horseshoe shaped fluid flow stator channels, said inlets of said high pressure generally horseshoe shaped fluid flow stator channels communicating with the outlets of said low pressure generally horseshoe shaped fluid flow stator channels,   the fluid in each of said generally horseshoe shaped fluid flow stator channels making multiple generally helical passes between said generally horseshoe shaped fluid flow stator channel and said impeller blades as the fluid proceeds from said inlet to said outlet of said generally horseshoe shaped fluid flow stator channel.   
     
     
       36. The gaseous fuel compression and control system of claim 3 wherein said helical flow compressor/turbine and permanent magnet motor/generator on a common shaft comprise: a housing;   a permanent magnet stator mounted within said housing at one end thereof;   a shaft rotatably supported within said housing by a pair of journal bearings;   a permanent magnet rotor mounted on said shaft between said pair of journal bearings, said permanent magnet rotor disposed on said shaft to rotate within said permanent magnet stator mounted at one end of said housing;   a low pressure impeller mounted at the other end of said shaft, said low pressure impeller having two rows each of a plurality of curved blades, with one row of said plurality of curved blades disposed on either side of the outer periphery of said low pressure impeller;   a medium pressure impeller mounted at the other end of said shaft adjacent to said low pressure impeller, said medium pressure impeller having two rows each of a plurality of curved blades, with one row of said plurality of curved blades disposed on either side of the outer periphery of said medium pressure impeller;   a high pressure impeller mounted at the other end of said shaft adjacent to said medium pressure impeller, said high pressure impeller having two rows each of a plurality of curved blades, with one row of said plurality of curved blades disposed on either side of the outer periphery of said high pressure impeller;   said housing including a first mid stator channel plate disposed between said low pressure impeller and said medium pressure impeller, a first pair of generally horseshoe shaped fluid flow stator channels with one of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of low pressure impeller curved blades and the other of said first pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of low pressure impeller curved blades, and a second pair of generally horseshoe shaped fluid flow stator channels with one of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of medium pressure impeller curved blades and the other of said second pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of medium pressure impeller curved blades,   said housing also including a second mid stator channel plate disposed between said medium pressure impeller and said high pressure impeller and a third pair of generally horseshoe shaped fluid flow stator channels with one of said third pair of generally horseshoe shaped fluid flow stator channels operably associated with one of said two rows of high pressure impeller curved blades and the other of said third pair of generally horseshoe shaped fluid flow stator channels operably associated with the other of said two rows of high pressure impeller curved blades,   said housing further including a low pressure stripper plate disposed radially outward of said low pressure impeller, a medium pressure stripper plate disposed radially outward of said medium pressure impeller, and a high pressure stripper plate disposed radially outward of said high pressure impeller, said low pressure stripper plate having a slightly greater thickness than said low pressure impeller, said medium pressure stripper plate having a slightly greater thickness than said medium pressure impeller, and said high pressure stripper plate having a slightly greater thickness than said high pressure impeller   said housing further including a fluid inlet at one end of each of said generally horseshoe shaped fluid flow stator channels, and a fluid outlet at the other end of each of said generally horseshoe shaped fluid flow stator channels, said inlets of said high pressure generally horseshoe shaped fluid flow stator channels communicating with the outlets of said medium pressure generally horseshoe shaped fluid flow stator channels and said inlets of said medium pressure generally horseshoe shaped fluid flow stator channels communicating with the outlets of said low pressure generally horseshoe shaped fluid flow stator channels and   the fluid in each of said generally horseshoe shaped fluid flow stator channels making multiple generally helical passes between said generally horseshoe shaped fluid flow stator channel and said impeller blades as the fluid proceeds from said inlet to said outlet of said generally horseshoe shaped fluid flow stator channel.